Processing facility

ABSTRACT

Biomass feedstocks (e.g., plant biomass, animal biomass, and municipal waste biomass) are processed to produce useful products, such as fuels. For example, systems are described that can use feedstock materials, such as cellulosic and/or lignocellulosic materials and/or starchy materials, to produce a product or intermediate, e.g., energy, a food, a fuel, or a material.

RELATED APPLICATIONS

This application is a continuation application of U.S. Application Ser.No. 151/141,281, filed Apr. 28, 2016, which is a continuationapplication of U.S. application Ser. No. 14/887,153, filed Oct. 19,2015, which is a continuation application of U.S. application Ser. No.14/494,815, filed Sep. 24, 2014, now U.S. Pat. No. 9,181,567, granted onNov. 10, 2015, which is a continuation application of U.S. applicationSer. No. 13/786,920, filed Mar. 6, 2013, now U.S. Pat. No. 8,877,467,granted on Nov. 4, 2014, which is a continuation application of U.S.application Ser. No. 12/704,519, filed Feb. 11, 2010, now U.S. Pat. No.8,415,122, granted on Apr. 9, 2013, which claims priority to U.S.Provisional Application Ser. No. 61/151,724, filed Feb. 11, 2009. Thecomplete disclosures of these applications are hereby incorporated byreference herein.

BACKGROUND

Various carbohydrates, such as cellulosic and lignocellulosic materials,e.g., in fibrous form, are produced, processed, and used in largequantities in a number of applications. Often such materials are usedonce, and then discarded as waste, or are simply considered to be wastematerials, e.g., sewage, bagasse, sawdust, and stover.

Various cellulosic and lignocellulosic materials, their uses, andapplications have been described in U.S. Pat. Nos. 7,307,108, 7,074,918,6,448,307, 6,258,876, 6,207,729, 5,973,035 and 5,952,105; and in variouspatent applications, including “FIBROUS MATERIALS AND COMPOSITES,”PCT/US2006/010648, filed on Mar. 23, 2006, AND “FIBROUS MATERIALS ANDCOMPOSITES,” U.S. Patent Application Publication No. 2007/0045456.

SUMMARY

Generally, this invention relates to processes for manufacturing anintermediate or a product, e.g., energy, a fuel such as ethanol, a foodor a material, from a plurality of different carbon-containingfeedstocks and/or from a feedstock having a variable composition. Thecarbon-containing feedstock may include, for example,carbohydrate-containing materials (e.g., starchy materials and/orcellulosic or lignocellulosic materials), and may in some cases be awaste material having an unpredictable or variable composition.

The processes disclosed herein, alone or in combination, change themolecular structure and/or recalcitrance level of the feedstock(s),allowing a desired product to be obtained from the feedstock in aneconomically feasible manner. The inventors have found that the amountof change to the structure and/or recalcitrance level of the feedstockrequired to produce a product varies as a function of the lignin contentof the feedstock. For example, the change in recalcitrance needed can bedirectly proportional to the lignin content. Accordingly, the methodsdisclosed herein involve adjusting the process type or one or moreprocess parameters used to manufacture the product to compensate forchanges in the lignin content of the feedstock that is being used, e.g.,applying a higher or lower dose or dose rate during the pretreatmentprocess used.

Many of the methods described herein can provide cellulosic and/orlignocellulosic materials that have, for example, a lower recalcitrancelevel, a lower molecular weight, a different level of functionalizationand/or crystallinity relative to a native material. Many of the methodsprovide materials that can be more readily utilized by a variety ofmicroorganisms, such as one or more homoacetogens or heteroacetogens(with or without enzymatic hydrolysis assistance) to produce usefulproducts, such as energy, fuels, foods and materials. Specific examplesof products include, but are not limited to, hydrogen, alcohols (e.g.,monohydric alcohols or dihydric alcohols, such as ethanol, n-propanol orn-butanol), sugars, biodiesel, organic acids (e.g., acetic acid and/orlactic acid), hydrocarbons, co-products (e.g., proteins, such ascellulolytic proteins (enzymes) or single cell proteins), and mixturesof any of these. Other examples include carboxylic acids, such as aceticacid or butyric acid, salts of a carboxylic acid, a mixture ofcarboxylic acids and salts of carboxylic acids and esters of carboxylicacids (e.g., methyl, ethyl and n-propyl esters), ketones, aldehydes,alpha, beta unsaturated acids, such as acrylic acid and olefins, such asethylene. Other alcohols and alcohol derivatives include propanol,propylene glycol, 1,4-butanediol, 1,3-propanediol, methyl or ethylesters of any of these alcohols. Other products include methyl acrylate,methylmethacrylate, lactic acid, propionic acid, butyric acid, succinicacid, 3-hydroxypropionic acid, a salt of any of the acids and a mixtureof any of the acids and respective salts.

Other products and intermediates, including food and pharmaceuticalproducts, are described in U.S. Provisional Application Ser. No.61/139,453, the full disclosure of which is hereby incorporated byreference herein in its entirety.

Many of the products obtained by the methods disclosed herein, such asethanol or n-butanol, can be utilized directly as a fuel or as a blendwith other components, such as gasoline, for powering cars, trucks,tractors, ships or trains, e.g., as an internal combustion fuel or as afuel cell feedstock. Other products described herein (e.g., organicacids, such as acetic acid and/or lactic acid) can be converted to othermoieties (e.g., esters or anhydrides) that can be converted and utilizedas a fuel. Many of the products obtained can also be utilized to poweraircraft, such as planes, e.g., having jet engines, or helicopters. Inaddition, the products described herein can be utilized for electricalpower generation, e.g., in a conventional steam generating plant or in afuel cell plant.

In one aspect, the invention features a method of making a productcomprising determining the lignin content of a biomass feedstock;treating the biomass feedstock material with a physical treatment;setting a process parameter of the process based on the lignin content;and converting at least a portion of the treated biomass feedstock,utilizing a microorganism, to produce a product or intermediate, such asenergy, fuels, foods or materials.

The physical treatment can be, for example, selected from the groupconsisting of mechanical treatment, radiation, sonication, pyrolysis,oxidation, steam explosion, chemical treatment, and combinationsthereof. Chemical treatment may include the use of a single chemical ortwo or more chemicals. Mechanical treatments include, for example,cutting, milling, pressing, grinding, shearing and chopping. Milling mayinclude, for example, ball milling, hammer milling, or other types ofmilling.

Some implementations include one or more of the following features. Thephysical treatment can comprise any one or more of the treatments listedabove, applied alone or in any desired combination, and applied once ormultiple times. In some cases, the physical treatment can compriseirradiating with ionizing radiation, alone or accompanied by mechanicaltreatment before and/or after irradiation. Irradiation can be performed,for example, with an electron beam.

The setting step can comprise setting the dosage of ionizing radiationto be delivered to the feedstock material. For example, a radiationdosage of 0.1 Mrad to 5.0 Mrad can be delivered per 1% by weight oflignin in the biomass feedstock, e.g., 0.25 Mrad to 4.0 Mrad or 0.3 Mradto 3.5 Mrad.

The intermediate or product can be, for example, any one or more of theproducts listed herein. In some cases, the product can be energy or afuel, for example biodiesel or an alcohol such as ethanol or methanol.The intermediate or product can also be, e.g., a carboxylic acid, anester of a carboxylic acid, a salt of a carboxylic acid, or a mixturethereof.

The method can further include repeating the determining, treating andsetting steps with a second feedstock.

In another aspect, the invention features a method of making a productor intermediate, the method including providing a cellulosic orlignocellulosic material having a plurality of pendent carboxylic acidgroups, mixing the material in a fluid that includes water to provide adispersion that has a first pH, and adding base to the dispersion toincrease its pH to a second pH higher than the first pH. The first pHcan be, for example, between 2.5 and 4.5, e.g., between 3 and 4.25. Thesecond pH can be, for example, between about 5 and 7, e.g., betweenabout 5.5 and 6.5.

Some implementations include one or more of the following features. Themethod can further include adding a cellulase to the dispersion tosaccharify the cellulosic or lignocellulosic material. The method canfurther include contacting the saccharified material with amicroorganism.

In some implementations, one or more components of the processingequipment, for example the mechanical treatment equipment, chemical(e.g., acid or base) treatment equipment, irradiating equipment,sonicating, pyrolyzing, oxidizing, steam exploding, saccharifying,and/or fermenting equipment, or any of the other equipment describedherein, may be portable, e.g., in the manner of the mobile processingequipment described in U.S. patent application Ser. No. 12/374,549, andPublished International Application No. WO 2008/011598, the fulldisclosures of which are incorporated herein by reference.

Changing a molecular structure of a material, as used herein, means tochange the chemical bonding arrangement or conformation of thestructure. For example, the change in the molecular structure caninclude changing the supramolecular structure of the material, oxidationof the material, changing an average molecular weight, changing anaverage crystallinity, changing a surface area, changing a degree ofpolymerization, changing a porosity, changing a degree of branching,grafting on other materials, changing a crystalline domain size, orchanging an overall domain size. A change in molecular structure may beeffected using any one or more of the physical treatments describedherein, alone or in any combination, applied once or repeatedly.

All publications, patent applications, patents, and other referencesmentioned herein or attached hereto are incorporated by reference intheir entirety for all that they contain.

DESCRIPTION OF THE DRAWINGS

FIG. 1 is a flow diagram illustrating a process for making a productfrom a carbon-containing feedstock having a variable lignin content.

FIG. 1A is a flow diagram illustrating steps of the process shown inFIG. 1 according to one implementation.

FIG. 2 is a schematic diagram illustrating a process for making ethanol.

FIG. 3 is a schematic of a processing facility to process alignocellulosic material.

DETAILED DESCRIPTION

Biomass feedstocks (e.g., plant biomass, animal biomass, and municipalwaste biomass) can be processed to a lower level of recalcitrance (ifnecessary) and converted into useful products such as those listed byway of example herein. Systems and processes are described herein thatuse readily abundant but often difficult to process materials, such ascellulosic or lignocellulosic materials which would otherwise be waste,e.g., crop residues and waste paper.

Generally, a manufacturing plant utilizing the processes describedherein will obtain a variety of different feedstocks in the course ofits operation. Some feedstocks may be relatively homogeneous incomposition, for example a shipment of corn cobs, while other feedstocksmay be of variable composition, for example municipal waste, e.g.,various waste paper streams.

Feedstocks can include, for example, paper, paper products, wood,wood-related materials, particle board, grasses, rice hulls, bagasse,cotton, jute, hemp, flax, bamboo, sisal, abaca, straw, corn cobs,coconut hair, algae, seaweed, altered celluloses, e.g., celluloseacetate, regenerated cellulose, and the like, or mixtures of any ofthese.

In some cases the biomass is a microbial material. Microbial sourcesinclude, but are not limited to, any naturally occurring or geneticallymodified microorganism or organism that contains or is capable ofproviding a source of carbohydrates (e.g., cellulose), for example,protists, e.g., animal protists (e.g., protozoa such as flagellates,amoeboids, ciliates, and sporozoa) and plant protists (e.g., algae suchalveolates, chlorarachniophytes, cryptomonads, euglenids, glaucophytes,haptophytes, red algae, stramenopiles, and viridaeplantae). Otherexamples include seaweed, plankton (e.g., macroplankton, mesoplankton,microplankton, nanoplankton, picoplankton, and femptoplankton),phytoplankton, bacteria (e.g., gram positive bacteria, gram negativebacteria, and extremophiles), yeast and/or mixtures of these. In someinstances, microbial biomass can be obtained from natural sources, e.g.,the ocean, lakes, bodies of water, e.g., salt water or fresh water, oron land. Alternatively or in addition, microbial biomass can be obtainedfrom culture systems, e.g., large scale dry and wet culture systems.

To allow the manufacturing plant to utilize these different types offeedstocks to produce one or more desired products, the manufacturingprocess is adjustable to compensate for variations and/or within thefeedstocks, e.g., to compensate for variations in the lignin content ofthe different feedstocks.

Many of the processes described herein can effectively lower therecalcitrance level of the feedstock, making it easier to process, suchas by bioprocessing (e.g., with any microorganism described herein, suchas a homoacetogen or a heteroacetogen, and/or any enzyme describedherein), thermal processing (e.g., gasification or pyrolysis) orchemical methods (e.g., acid hydrolysis or oxidation). Biomass feedstockcan be treated or processed using one or more of any of the methodsdescribed herein, such as mechanical treatment, chemical treatment,radiation, sonication, oxidation, pyrolysis or steam explosion. Thevarious treatment systems and methods can be used in combinations oftwo, three, or even four or more of these technologies or othersdescribed herein and elsewhere.

As shown in FIG. 1, in some implementations the lignin content of theincoming feedstock is determined (step 100), and then, based on thelignin content, the type of physical treatment(s) (e.g., mechanicaltreatment, radiation, sonication, etc.) and/or one or more processingconditions required to obtain the desired product are determined (step102). If the feedstock has a relatively high level of variability, e.g.,municipal waste, a number of samples may be taken and the average lignincontent calculated. In some cases, the feedstock may be pre-treated tohomogenize it prior to lignin content measurement, for example bygrinding or pulverizing, e.g., freeze-grinding (e.g., as disclosed inU.S. Provisional Application No. 61/081,709, filed Jul. 17, 2008, thefull disclosure of which is incorporated herein by reference). In somecases, e.g., as shown in FIG. 1A, two or more incoming feedstocks can bemixed together to form a combined feedstock, and the lignin content ofthe combined feedstock can be measured.

Methods for preparing samples and determining lignin content aredisclosed in Department of Energy (DOE) test proceduresNREL/TP-510-42618 (Revised April 2008), NREL/TP-510-42619 (RevisedJanuary 2008), and NREL/TP-510-42620 (Revised January 2008).

Once the lignin content has been determined, it can be used, e.g., basedon empirically determined relationships between lignin content andrecalcitrance, to determine the processing conditions, which are theninput to the processing equipment (step 104). For example, as shown inFIG. 1A, the parameters may be those used in one or morerecalcitrance-reducing process steps that will change the structureand/or reduce the recalcitrance of the feedstock, as will be describedin further detail below.

If desired, the output of the process can be monitored (step 106, FIG.1), and the process parameters adjusted based on these measurements(step 108, FIG. 1). For example, the volume, purity, or othercharacteristics of the output can be measured. The output may be thefinal product, or may be an intermediate product, such as alignocellulosic or cellulosic material having reduced recalcitrance.

Referring now to FIG. 2, in one example the methodology discussed abovecan be integrated into a process for manufacturing a product, e.g.,energy, fuel, food or material, for example an alcohol such as ethanol.Such a process can include, for example, mechanically treating thefeedstock (step 110), before and/or after this treatment, treating thefeedstock with another physical treatment, for example irradiation, tofurther reduce its recalcitrance (step 112), and then processing thetreated feedstock to produce a desired product (step 114) which isoutput, e.g., by distillation (step 116). The individual steps of thisprocess will be described in detail below. The steps of measuring lignincontent (step 118) and setting or adjusting process parameters (step120) can be performed at various stages of the process, for example justprior to the process step(s) used to change the structure of thefeedstock, as shown.

FIG. 3 shows a schematic of a processing facility to process alignocellulosic material to a product.

Biomass Materials

The biomass can be, e.g., a cellulosic or lignocellulosic material. Suchmaterials include paper and paper products (e.g., polycoated paper andKraft paper), wood, wood-related materials, e.g., particle board,grasses, rice hulls, bagasse, jute, hemp, flax, bamboo, sisal, abaca,straw, corn cobs, coconut hair; and materials high in α-cellulosecontent, e.g., cotton. Feedstocks can be obtained from virgin scraptextile materials, e.g., remnants, post consumer waste, e.g., rags. Whenpaper products are used they can be virgin materials, e.g., scrap virginmaterials, or they can be post-consumer waste. Aside from virgin rawmaterials, post-consumer, industrial (e.g., offal), and processing waste(e.g., effluent from paper processing) can also be used as fibersources. Biomass feedstocks can also be obtained or derived from human(e.g., sewage), animal or plant wastes. Additional cellulosic andlignocellulosic materials have been described in U.S. Pat. Nos.6,448,307, 6,258,876, 6,207,729, 5,973,035 and 5,952,105.

In some embodiments, the biomass material includes a carbohydrate thatis or includes a material having one or more β-1,4-linkages and having anumber average molecular weight between about 3,000 and 50,000. Such acarbohydrate is or includes cellulose (I), which is derived from(β-glucose 1) through condensation of β(1,4)-glycosidic bonds. Thislinkage contrasts itself with that for α(1,4)-glycosidic bonds presentin starch and other carbohydrates.

Starchy materials include starch itself, e.g., corn starch, wheatstarch, potato starch or rice starch, a derivative of starch, or amaterial that includes starch, such as an edible food product or a crop.For example, the starchy material can be arracacha, buckwheat, banana,barley, cassava, kudzu, oca, sago, sorghum, regular household potatoes,sweet potato, taro, yams, or one or more beans, such as favas, lentilsor peas. Blends of any two or more starchy materials are also starchymaterials. In particular embodiments, the starchy material is derivedfrom corn. Various corn starches and derivatives are described in “CornStarch,” Corn Refiners Association (11^(th) Edition, 2006).

In some cases the biomass is a microbial material. Microbial sourcesinclude, but are not limited to, any naturally occurring or geneticallymodified microorganism or organism that contains or is capable ofproviding a source of carbohydrates (e.g., cellulose), for example,protists, e.g., animal protists (e.g., protozoa such as flagellates,amoeboids, ciliates, and sporozoa) and plant protists (e.g., algae suchalveolates, chlorarachniophytes, cryptomonads, euglenids, glaucophytes,haptophytes, red algae, stramenopiles, and viridaeplantae). Otherexamples include seaweed, plankton (e.g., macroplankton, mesoplankton,microplankton, nanoplankton, picoplankton, and femptoplankton),phytoplankton, bacteria (e.g., gram positive bacteria, gram negativebacteria, and extremophiles), yeast and/or mixtures of these. In someinstances, microbial biomass can be obtained from natural sources, e.g.,the ocean, lakes, bodies of water, e.g., salt water or fresh water, oron land. Alternatively or in addition, microbial biomass can be obtainedfrom culture systems, e.g., large scale dry and wet culture systems.

Examples of Other Blends

Blends of the biomass feedstock with other materials, e.g.,carbon-containing materials such as pre-coal or coal, e.g., peat,lignite, sub-bituminous, bituminous and anthracite, oil sand, oil shalecan also be utilized. In addition, blends of any biomass materialsdescribed herein with other carbon-containing material can be utilizedfor making any of the products described herein, such as ethanol, aceticacid or ethyl acetate.

Physical Treatment

Physical treatment processes can include one or more of any of thosedescribed herein, such as mechanical treatment, chemical treatment,irradiation, sonication, oxidation, pyrolysis or steam explosion.Treatment methods can be used in combinations of two, three, four, oreven all of these technologies (in any order). When more than onetreatment methods is used, the methods can be applied at the same timeor at different times. Other processes that change a molecular structureof a biomass feedstock may also be used, alone or in combination withthe processes disclosed herein.

One or more of the treatment processes described below may be includedin the recalcitrance reducing operating unit discussed above.Alternatively, or in addition, other processes for reducingrecalcitrance may be included.

Mechanical Treatments

In some cases, methods can include mechanically treating the biomassfeedstock. Mechanical treatments include, for example, cutting, milling,pressing, grinding, shearing and chopping. Milling may include, forexample, ball milling, hammer milling, rotor/stator dry or wet milling,or other types of milling. Other mechanical treatments include, e.g.,stone grinding, cracking, mechanical ripping or tearing, pin grinding orair attrition milling.

Mechanical treatment can be advantageous for “opening up,” “stressing,”breaking and shattering the cellulosic or lignocellulosic materials,making the cellulose of the materials more susceptible to chain scissionand/or reduction of crystallinity. The open materials can also be moresusceptible to oxidation when irradiated.

In some cases, the mechanical treatment may include an initialpreparation of the feedstock as received, e.g., size reduction ofmaterials, such as by cutting, grinding, shearing, pulverizing orchopping. For example, in some cases, loose feedstock (e.g., recycledpaper, starchy materials, or switchgrass) is prepared by shearing orshredding.

Alternatively, or in addition, the feedstock material can be physicallytreated by one or more of the other physical treatment methods, e.g.,chemical treatment, radiation, sonication, oxidation, pyrolysis or steamexplosion, and then mechanically treated. This sequence can beadvantageous since materials treated by one or more of the othertreatments, e.g., irradiation or pyrolysis, tend to be more brittle and,therefore, it may be easier to further change the molecular structure ofthe material by mechanical treatment.

In some embodiments, the feedstock material is in the form of a fibrousmaterial, and mechanical treatment includes shearing to expose fibers ofthe fibrous material. Shearing can be performed, for example, using arotary knife cutter. Other methods of mechanically treating thefeedstock include, for example, milling or grinding. Milling may beperformed using, for example, a hammer mill, ball mill, colloid mill,conical or cone mill, disk mill, edge mill, Wiley mill or grist mill.Grinding may be performed using, for example, a stone grinder, pingrinder, coffee grinder, or burr grinder. Grinding may be provided, forexample, by a reciprocating pin or other element, as is the case in apin mill. Other mechanical treatment methods include mechanical rippingor tearing, other methods that apply pressure to the fibers, and airattrition milling. Suitable mechanical treatments further include anyother technique that changes the molecular structure of the feedstock.

If desired, the mechanically treated material can be passed through ascreen, e.g., having an average opening size of 1.59 mm or less ( 1/16inch, 0.0625 inch). In some embodiments, shearing, or other mechanicaltreatment, and screening are performed concurrently. For example, arotary knife cutter can be used to concurrently shear the and screen thefeedstock. The feedstock is sheared between stationary blades androtating blades to provide a sheared material that passes through ascreen, and is captured in a bin. The bin can have a pressure belownominal atmospheric pressure, e.g., at least 10 percent below nominalatmospheric pressure, e.g., at least 25 percent below nominalatmospheric pressure, at least 50 percent below nominal atmosphericpressure, or at least 75 percent below nominal atmospheric pressure. Insome embodiments, a vacuum source is utilized to maintain the bin belownominal atmospheric pressure.

The cellulosic or lignocellulosic material can be mechanically treatedin a dry state (e.g., having little or no free water on its surface), ahydrated state (e.g., having up to ten percent by weight absorbedwater), or in a wet state, e.g., having between about 10 percent andabout 75 percent by weight water. The fiber source can even bemechanically treated while partially or fully submerged under a liquid,such as water, ethanol or isopropanol.

The cellulosic or lignocellulosic material can also be mechanicallytreated under a gas (such as a stream or atmosphere of gas other thanair), e.g., oxygen or nitrogen, or steam.

If desired, lignin can be removed from any of the fibrous materials thatinclude lignin. Also, to aid in the breakdown of the materials thatinclude cellulose, the material can be treated prior to or duringmechanical treatment or irradiation with heat, a chemical (e.g., mineralacid, base or a strong oxidizer such as sodium hypochlorite) and/or anenzyme. For example, grinding can be performed in the presence of anacid.

Mechanical treatment systems can be configured to produce streams withspecific characteristics such as, for example, specific maximum sizes,specific length-to-width, or specific surface areas ratios. Mechanicaltreatment can increase the rate of reactions or reduce the processingtime required by opening up the materials and making them moreaccessible to processes and/or reagents, such as reagents in a solution.The bulk density of feedstocks can also be controlled using mechanicaltreatment. For example, in some embodiments, after mechanical treatmentthe material has a bulk density of less than 0.25 g/cm³, e.g., 0.20g/cm³, 0.15 g/cm³, 0.10 g/cm³, 0.05 g/cm³ or less, e.g., 0.025 g/cm³.Bulk density is determined using ASTM D1895B. Briefly, the methodinvolves filling a measuring cylinder of known volume with a sample andobtaining a weight of the sample. The bulk density is calculated bydividing the weight of the sample in grams by the known volume of thecylinder in cubic centimeters.

If the feedstock is a fibrous material the fibers of the mechanicallytreated material can have a relatively large average length-to-diameterratio (e.g., greater than 20-to-1), even if they have been sheared morethan once. In addition, the fibers of the fibrous materials describedherein may have a relatively narrow length and/or length-to-diameterratio distribution.

As used herein, average fiber widths (e.g., diameters) are thosedetermined optically by randomly selecting approximately 5,000 fibers.Average fiber lengths are corrected length-weighted lengths. BET(Brunauer, Emmet and Teller) surface areas are multi-point surfaceareas, and porosities are those determined by mercury porosimetry.

If the feedstock is a fibrous material the average length-to-diameterratio of fibers of the mechanically treated material can be, e.g.,greater than 8/1, e.g., greater than 10/1, greater than 15/1, greaterthan 20/1, greater than 25/1, or greater than 50/1. An average fiberlength of the mechanically treated material can be, e.g., between about0.5 mm and 2.5 mm, e.g., between about 0.75 mm and 1.0 mm, and anaverage width (e.g., diameter) of the second fibrous material 14 can be,e.g., between about 5 μm and 50 μm, e.g., between about 10 μm and 30 μm.

In some embodiments, if the feedstock is a fibrous material the standarddeviation of the fiber length of the mechanically treated material canbe less than 60 percent of an average fiber length of the mechanicallytreated material, e.g., less than 50 percent of the average length, lessthan 40 percent of the average length, less than 25 percent of theaverage length, less than 10 percent of the average length, less than 5percent of the average length, or even less than 1 percent of theaverage length.

In some embodiments, a BET surface area of the mechanically treatedmaterial is greater than 0.1 m²/g, e.g., greater than 0.25 m²/g, greaterthan 0.5 m²/g, greater than 1.0 m²/g, greater than 1.5 m²/g, greaterthan 1.75 m²/g, greater than 5.0 m²/g, greater than 10 m²/g, greaterthan 25 m²/g, greater than 35 m²/g, greater than 50 m²/g, greater than60 m²/g, greater than 75 m²/g, greater than 100 m²/g, greater than 150m²/g, greater than 200 m²/g, or even greater than 250 m²/g.

A porosity of the mechanically treated material can be, e.g., greaterthan 20 percent, greater than 25 percent, greater than 35 percent,greater than 50 percent, greater than 60 percent, greater than 70percent, greater than 80 percent, greater than 85 percent, greater than90 percent, greater than 92 percent, greater than 94 percent, greaterthan 95 percent, greater than 97.5 percent, greater than 99 percent, oreven greater than 99.5 percent.

In some situations, it can be desirable to prepare a low bulk densitymaterial, densify the material (e.g., to make it easier and less costlyto transport to another site), and then revert the material to a lowerbulk density state. Densified materials can be processed by any of themethods described herein, or any material processed by any of themethods described herein can be subsequently densified, e.g., asdisclosed in WO 2008/073186.

Radiation Treatment

One or more radiation processing sequences can be used to process thefeedstock, and to provide a structurally modified material whichfunctions as input to further processing steps and/or sequences.Irradiation can, for example, reduce the molecular weight and/orcrystallinity of feedstock. In some embodiments, energy deposited in amaterial that releases an electron from its atomic orbital is used toirradiate the materials. The radiation may be provided by 1) heavycharged particles, such as alpha particles or protons, 2) electrons,produced, for example, in beta decay or electron beam accelerators, or3) electromagnetic radiation, for example, gamma rays, x rays, orultraviolet rays. In one approach, radiation produced by radioactivesubstances can be used to irradiate the feedstock. In some embodiments,any combination in any order or concurrently of (1) through (3) may beutilized. In another approach, electromagnetic radiation (e.g., producedusing electron beam emitters) can be used to irradiate the feedstock.The doses applied depend on the desired effect and the particularfeedstock. For example, high doses of radiation can break chemical bondswithin feedstock components. In some instances when chain scission isdesirable and/or polymer chain functionalization is desirable, particlesheavier than electrons, such as protons, helium nuclei, argon ions,silicon ions, neon ions, carbon ions, phoshorus ions, oxygen ions ornitrogen ions can be utilized. When ring-opening chain scission isdesired, positively charged particles can be utilized for their Lewisacid properties for enhanced ring-opening chain scission. For example,when maximum oxidation is desired, oxygen ions can be utilized, and whenmaximum nitration is desired, nitrogen ions can be utilized.

In one method, a first material that is or includes cellulose having afirst number average molecular weight (M_(N1)) is irradiated, e.g., bytreatment with ionizing radiation (e.g., in the form of gamma radiation,X-ray radiation, 100 nm to 280 nm ultraviolet (UV) light, a beam ofelectrons or other charged particles) to provide a second material thatincludes cellulose having a second number average molecular weight(M_(N2)) lower than the first number average molecular weight. Thesecond material (or the first and second material) can be combined witha microorganism (with or without enzyme treatment) that can utilize thesecond and/or first material or its constituent sugars or lignin toproduce a fuel or other useful product that is or includes hydrogen, analcohol (e.g., ethanol or butanol, such as n-, sec- or t-butanol), anorganic acid, a hydrocarbon or mixtures of any of these.

Since the second material has cellulose having a reduced molecularweight relative to the first material, and in some instances, a reducedcrystallinity as well, the second material is generally moredispersible, swellable and/or soluble in a solution containing amicroorganism and/or an enzyme. These properties make the secondmaterial more susceptible to chemical, enzymatic and/or biologicalattack relative to the first material, which can greatly improve theproduction rate and/or production level of a desired product, e.g.,ethanol. Radiation can also sterilize the materials, or any media neededto bioprocess the material.

In some embodiments, the second number average molecular weight (M_(N2))is lower than the first number average molecular weight (M_(N1)) by morethan about 10 percent, e.g., 15, 20, 25, 30, 35, 40, 50 percent, 60percent, or even more than about 75 percent.

In some instances, the second material has cellulose that has ascrystallinity (C₂) that is lower than the crystallinity (C₁) of thecellulose of the first material. For example, (C₂) can be lower than(C₁) by more than about 10 percent, e.g., 15, 20, 25, 30, 35, 40, oreven more than about 50 percent.

In some embodiments, the starting crystallinity index (prior toirradiation) is from about 40 to about 87.5 percent, e.g., from about 50to about 75 percent or from about 60 to about 70 percent, and thecrystallinity index after irradiation is from about 10 to about 50percent, e.g., from about 15 to about 45 percent or from about 20 toabout 40 percent. However, in some embodiments, e.g., after extensiveirradiation, it is possible to have a crystallinity index of lower than5 percent. In some embodiments, the material after irradiation issubstantially amorphous.

In some embodiments, the starting number average molecular weight (priorto irradiation) is from about 200,000 to about 3,200,000, e.g., fromabout 250,000 to about 1,000,000 or from about 250,000 to about 700,000,and the number average molecular weight after irradiation is from about50,000 to about 200,000, e.g., from about 60,000 to about 150,000 orfrom about 70,000 to about 125,000. However, in some embodiments, e.g.,after extensive irradiation, it is possible to have a number averagemolecular weight of less than about 10,000 or even less than about5,000.

In some embodiments, the second material can have a level of oxidation(O₂) that is higher than the level of oxidation (O₁) of the firstmaterial. A higher level of oxidation of the material can aid in itsdispersability, swellability and/or solubility, further enhancing thematerial's susceptibility to chemical, enzymatic or biological attack.In some embodiments, to increase the level of the oxidation of thesecond material relative to the first material, the irradiation isperformed under an oxidizing environment, e.g., under a blanket of airor oxygen, producing a second material that is more oxidized than thefirst material. For example, the second material can have more hydroxylgroups, aldehyde groups, ketone groups, ester groups or carboxylic acidgroups, which can increase its hydrophilicity.

Ionizing Radiation

Each form of radiation ionizes the carbon-containing material viaparticular interactions, as determined by the energy of the radiation.Heavy charged particles primarily ionize matter via Coulomb scattering;furthermore, these interactions produce energetic electrons that mayfurther ionize matter. Alpha particles are identical to the nucleus of ahelium atom and are produced by the alpha decay of various radioactivenuclei, such as isotopes of bismuth, polonium, astatine, radon,francium, radium, several actinides, such as actinium, thorium, uranium,neptunium, curium, californium, americium, and plutonium.

When particles are utilized, they can be neutral (uncharged), positivelycharged or negatively charged. When charged, the charged particles canbear a single positive or negative charge, or multiple charges, e.g.,one, two, three or even four or more charges. In instances in whichchain scission is desired, positively charged particles may bedesirable, in part due to their acidic nature. When particles areutilized, the particles can have the mass of a resting electron, orgreater, e.g., 500, 1000, 1500, 2000, 10,000 or even 100,000 times themass of a resting electron. For example, the particles can have a massof from about 1 atomic unit to about 150 atomic units, e.g., from about1 atomic unit to about 50 atomic units, or from about 1 to about 25,e.g., 1, 2, 3, 4, 5, 10, 12 or 15 amu. Accelerators used to acceleratethe particles can be electrostatic DC, electrodynamic DC, RF linear,magnetic induction linear or continuous wave. For example, cyclotrontype accelerators are available from IBA, Belgium, such as theRhodatron® system, while DC type accelerators are available from RDI,now IBA Industrial, such as the Dynamitron®. Ions and ion acceleratorsare discussed in Introductory Nuclear Physics, Kenneth S. Krane, JohnWiley & Sons, Inc. (1988), Krsto Prelec, FIZIKA B 6 (1997) 4, 177-206,Chu, William T., “Overview of Light-Ion Beam Therapy” Columbus-Ohio,ICRU-IAEA Meeting, 18-20 Mar. 2006, Iwata, Y. et al.,“Alternating-Phase-Focused IH-DTL for Heavy-Ion Medical Accelerators”Proceedings of EPAC 2006, Edinburgh, Scotland and Leaner, C. M. et al.,“Status of the Superconducting ECR Ion Source Venus” Proceedings of EPAC2000, Vienna, Austria.

Gamma radiation has the advantage of a significant penetration depthinto a variety of materials. Sources of gamma rays include radioactivenuclei, such as isotopes of cobalt, calcium, technicium, chromium,gallium, indium, iodine, iron, krypton, samarium, selenium, sodium,thalium, and xenon.

Sources of x rays include electron beam collision with metal targets,such as tungsten or molybdenum or alloys, or compact light sources, suchas those produced commercially by Lyncean.

Sources for ultraviolet radiation include deuterium or cadmium lamps.

Sources for infrared radiation include sapphire, zinc, or selenidewindow ceramic lamps.

Sources for microwaves include klystrons, Slevin type RF sources, oratom beam sources that employ hydrogen, oxygen, or nitrogen gases.

In some embodiments, a beam of electrons is used as the radiationsource. A beam of electrons has the advantages of high dose rates (e.g.,1, 5, or even 10 Mrad per second), high throughput, less containment,and less confinement equipment. Electrons can also be more efficient atcausing chain scission. In addition, electrons having energies of 4-10MeV can have a penetration depth of 5 to 30 mm or more, such as 40 mm.

Electron beams can be generated, e.g., by electrostatic generators,cascade generators, transformer generators, low energy accelerators witha scanning system, low energy accelerators with a linear cathode, linearaccelerators, and pulsed accelerators. Electrons as an ionizingradiation source can be useful, e.g., for relatively thin piles ofmaterials, e.g., less than 0.5 inch, e.g., less than 0.4 inch, 0.3 inch,0.2 inch, or less than 0.1 inch. In some embodiments, the energy of eachelectron of the electron beam is from about 0.3 MeV to about 2.0 MeV(million electron volts), e.g., from about 0.5 MeV to about 1.5 MeV, orfrom about 0.7 MeV to about 1.25 MeV.

Electron beam irradiation devices may be procured commercially from IonBeam Applications, Louvain-la-Neuve, Belgium or the Titan Corporation,San Diego, Calif. Typical electron energies can be 1 MeV, 2 MeV, 4.5MeV, 7.5 MeV, or 10 MeV. Typical electron beam irradiation device powercan be 1 kW, 5 kW, 10 kW, 20 kW, 50 kW, 100 kW, 250 kW, or 500 kW. Thelevel of depolymerization of the feedstock depends on the electronenergy used and the dose applied, while exposure time depends on thepower and dose. Typical doses may take values of 1 kGy, 5 kGy, 10 kGy,20 kGy, 50 kGy, 100 kGy, or 200 kGy.

Ion Particle Beams

Particles heavier than electrons can be utilized to irradiate materials,such as carbohydrates or materials that include carbohydrates, e.g.,cellulosic materials, lignocellulosic materials, starchy materials, ormixtures of any of these and others described herein. For example,protons, helium nuclei, argon ions, silicon ions, neon ions carbon ions,phoshorus ions, oxygen ions or nitrogen ions can be utilized. In someembodiments, particles heavier than electrons can induce higher amountsof chain scission (relative to lighter particles). In some instances,positively charged particles can induce higher amounts of chain scissionthan negatively charged particles due to their acidity.

Heavier particle beams can be generated, e.g., using linear acceleratorsor cyclotrons. In some embodiments, the energy of each particle of thebeam is from about 1.0 MeV/atomic unit to about 6,000 MeV/atomic unit,e.g., from about 3 MeV/atomic unit to about 4,800 MeV/atomic unit, orfrom about 10 MeV/atomic unit to about 1,000 MeV/atomic unit.

In certain embodiments, ion beams used to irradiate carbon-containingmaterials, e.g., biomass materials, can include more than one type ofion. For example, ion beams can include mixtures of two or more (e.g.,three, four or more) different types of ions. Exemplary mixtures caninclude carbon ions and protons, carbon ions and oxygen ions, nitrogenions and protons, and iron ions and protons. More generally, mixtures ofany of the ions discussed above (or any other ions) can be used to formirradiating ion beams. In particular, mixtures of relatively light andrelatively heavier ions can be used in a single ion beam.

In some embodiments, ion beams for irradiating materials includepositively-charged ions. The positively charged ions can include, forexample, positively charged hydrogen ions (e.g., protons), noble gasions (e.g., helium, neon, argon), carbon ions, nitrogen ions, oxygenions, silicon atoms, phosphorus ions, and metal ions such as sodiumions, calcium ions, and/or iron ions. Without wishing to be bound by anytheory, it is believed that such positively-charged ions behavechemically as Lewis acid moieties when exposed to materials, initiatingand sustaining cationic ring-opening chain scission reactions in anoxidative environment.

In certain embodiments, ion beams for irradiating materials includenegatively-charged ions. Negatively charged ions can include, forexample, negatively charged hydrogen ions (e.g., hydride ions), andnegatively charged ions of various relatively electronegative nuclei(e.g., oxygen ions, nitrogen ions, carbon ions, silicon ions, andphosphorus ions). Without wishing to be bound by any theory, it isbelieved that such negatively-charged ions behave chemically as Lewisbase moieties when exposed to materials, causing anionic ring-openingchain scission reactions in a reducing environment.

In some embodiments, beams for irradiating materials can include neutralatoms. For example, any one or more of hydrogen atoms, helium atoms,carbon atoms, nitrogen atoms, oxygen atoms, neon atoms, silicon atoms,phosphorus atoms, argon atoms, and iron atoms can be included in beamsthat are used for irradiation of biomass materials. In general, mixturesof any two or more of the above types of atoms (e.g., three or more,four or more, or even more) can be present in the beams.

In certain embodiments, ion beams used to irradiate materials includesingly-charged ions such as one or more of H⁺, H⁻, He⁺, Ne⁺, Ar⁺, C⁺,C⁻, O⁺, O⁻, N⁺, N⁻, Si⁺, Si⁻, P⁺, P⁻, Na⁺, Ca⁺, and Fe⁺. In someembodiments, ion beams can include multiply-charged ions such as one ormore of C²⁺, C³⁺, C⁴⁺, N³⁺, N⁵⁺, N³⁻, O²⁺, O²⁻, O₂ ²⁻, Si²⁺, Si⁴⁺, Si²⁻,and Si⁴⁻. In general, the ion beams can also include more complexpolynuclear ions that bear multiple positive or negative charges. Incertain embodiments, by virtue of the structure of the polynuclear ion,the positive or negative charges can be effectively distributed oversubstantially the entire structure of the ions. In some embodiments, thepositive or negative charges can be somewhat localized over portions ofthe structure of the ions.

Electromagnetic Radiation

In embodiments in which the irradiating is performed withelectromagnetic radiation, the electromagnetic radiation can have, e.g.,energy per photon (in electron volts) of greater than 10² eV, e.g.,greater than 10³, 10⁴, 10⁵, 10⁶, or even greater than 10⁷ eV. In someembodiments, the electromagnetic radiation has energy per photon ofbetween 10⁴ and 10⁷, e.g., between 10⁵ and 10⁶ eV. The electromagneticradiation can have a frequency of, e.g., greater than 10¹⁶ hz, greaterthan 10¹⁷ hz, 10¹⁸, 10¹⁹, 10²⁰, or even greater than 10²¹ hz. In someembodiments, the electromagnetic radiation has a frequency of between10¹⁸ and 10²² hz, e.g., between 10¹⁹ to 10²¹ hz.

Doses

The dose of radiation will depend on the lignin content of thefeedstock. For example, in some cases 0.1 Mrad to 5.0 Mrad is deliveredper 1% by weight of lignin in the biomass feedstock, e.g. 0.25 Mrad to4.0 Mrad, or 0.3 Mrad to 3.5 Mrad per 1%.

In some embodiments, the irradiating (with any radiation source or acombination of sources) is performed until the material receives a doseof at least 0.25 Mrad, e.g., at least 1.0 Mrad, at least 2.5 Mrad, atleast 5.0 Mrad, or at least 10.0 Mrad. In some embodiments, theirradiating is performed until the material receives a dose of between1.0 Mrad and 6.0 Mrad, e.g., between 1.5 Mrad and 4.0 Mrad.

In some embodiments, the irradiating is performed at a dose rate ofbetween 5.0 and 1500.0 kilorads/hour, e.g., between 10.0 and 750.0kilorads/hour or between 50.0 and 350.0 kilorads/hours.

In some embodiments, two or more radiation sources are used, such as twoor more ionizing radiations. For example, samples can be treated, in anyorder, with a beam of electrons, followed by gamma radiation and UVlight having wavelengths from about 100 nm to about 280 nm. In someembodiments, samples are treated with three ionizing radiation sources,such as a beam of electrons, gamma radiation, and energetic UV light.

Sonication

One or more sonication processing sequences can be used to processmaterials from a wide variety of different sources to extract usefulsubstances from the materials, and to provide partially degraded organicmaterial (when organic materials are employed) which functions as inputto further processing steps and/or sequences. Sonication can reduce themolecular weight and/or crystallinity of the materials, such as one ormore of any of the materials described herein, e.g., one or morecarbohydrate sources, such as cellulosic or lignocellulosic materials,or starchy materials. As discussed above with regard to radiation, theprocess parameters used for sonication will vary depending on the lignincontent of the feedstock. For example, feedstocks with higher ligninlevels generally require a higher residence time and/or energy level,resulting in a higher total energy delivered to the feedstock.

In one method, a first material that includes cellulose having a firstnumber average molecular weight (M_(N1)) is dispersed in a medium, suchas water, and sonicated and/or otherwise cavitated, to provide a secondmaterial that includes cellulose having a second number averagemolecular weight (M_(N2)) lower than the first number average molecularweight. The second material (or the first and second material in certainembodiments) can be combined with a microorganism (with or withoutenzyme treatment) that can utilize the second and/or first material toproduce a fuel that is or includes hydrogen, an alcohol, an organicacid, a hydrocarbon or mixtures of any of these.

Since the second material has cellulose having a reduced molecularweight relative to the first material, and in some instances, a reducedcrystallinity as well, the second material is generally moredispersible, swellable, and/or soluble in a solution containing themicroorganism, e.g., at a concentration of greater than 10⁶microorganisms/mL. These properties make the second material moresusceptible to chemical, enzymatic, and/or microbial attack relative tothe first material, which can greatly improve the production rate and/orproduction level of a desired product, e.g., ethanol. Sonication canalso sterilize the materials, but should not be used while themicroorganisms are supposed to be alive.

In some embodiments, the second number average molecular weight (M_(N2))is lower than the first number average molecular weight (M_(N1)) by morethan about 10 percent, e.g., 15, 20, 25, 30, 35, 40, 50 percent, 60percent, or even more than about 75 percent.

In some instances, the second material has cellulose that has ascrystallinity (C₂) that is lower than the crystallinity (C₁) of thecellulose of the first material. For example, (C₂) can be lower than(C₁) by more than about 10 percent, e.g., 15, 20, 25, 30, 35, 40, oreven more than about 50 percent.

In some embodiments, the starting crystallinity index (prior tosonication) is from about 40 to about 87.5 percent, e.g., from about 50to about 75 percent or from about 60 to about 70 percent, and thecrystallinity index after sonication is from about 10 to about 50percent, e.g., from about 15 to about 45 percent or from about 20 toabout 40 percent. However, in certain embodiments, e.g., after extensivesonication, it is possible to have a crystallinity index of lower than 5percent. In some embodiments, the material after sonication issubstantially amorphous.

In some embodiments, the starting number average molecular weight (priorto sonication) is from about 200,000 to about 3,200,000, e.g., fromabout 250,000 to about 1,000,000 or from about 250,000 to about 700,000,and the number average molecular weight after sonication is from about50,000 to about 200,000, e.g., from about 60,000 to about 150,000 orfrom about 70,000 to about 125,000. However, in some embodiments, e.g.,after extensive sonication, it is possible to have a number averagemolecular weight of less than about 10,000 or even less than about5,000.

In some embodiments, the second material can have a level of oxidation(O₂) that is higher than the level of oxidation (O₁) of the firstmaterial. A higher level of oxidation of the material can aid in itsdispersability, swellability and/or solubility, further enhancing thematerial's susceptibility to chemical, enzymatic or microbial attack. Insome embodiments, to increase the level of the oxidation of the secondmaterial relative to the first material, the sonication is performed inan oxidizing medium, producing a second material that is more oxidizedthan the first material. For example, the second material can have morehydroxyl groups, aldehyde groups, ketone groups, ester groups orcarboxylic acid groups, which can increase its hydrophilicity.

In some embodiments, the sonication medium is an aqueous medium. Ifdesired, the medium can include an oxidant, such as a peroxide (e.g.,hydrogen peroxide), a dispersing agent and/or a buffer. Examples ofdispersing agents include ionic dispersing agents, e.g., sodium laurylsulfate, and non-ionic dispersing agents, e.g., poly(ethylene glycol).

In other embodiments, the sonication medium is non-aqueous. For example,the sonication can be performed in a hydrocarbon, e.g., toluene orheptane, an ether, e.g., diethyl ether or tetrahydrofuran, or even in aliquefied gas such as argon, xenon, or nitrogen.

Pyrolysis

One or more pyrolysis processing sequences can be used to processcarbon-containing materials from a wide variety of different sources toextract useful substances from the materials, and to provide partiallydegraded materials which function as input to further processing stepsand/or sequences. Feedstocks with higher lignin levels generally requirea higher temperature, longer residence time, and/or introduction ofhigher levels of oxygen during pyrolysis.

In one example, a first material that includes cellulose having a firstnumber average molecular weight (M_(N1)) is pyrolyzed, e.g., by heatingthe first material in a tube furnace (in the presence or absence ofoxygen), to provide a second material that includes cellulose having asecond number average molecular weight (M_(N2)) lower than the firstnumber average molecular weight. The second material (or the first andsecond material in certain embodiments) is/are combined with amicroorganism (with or without acid or enzymatic hydrolysis) that canutilize the second and/or first material to produce a fuel that is orincludes hydrogen, an alcohol (e.g., ethanol or butanol, such as n-, secor t-butanol), an organic acid, a hydrocarbon or mixtures of any ofthese.

Since the second material has cellulose having a reduced molecularweight relative to the first material, and in some instances, a reducedcrystallinity as well, the second material is generally moredispersible, swellable and/or soluble in a solution containing themicroorganism, e.g., at a concentration of greater than 10⁶microorganisms/mL. These properties make the second material moresusceptible to chemical, enzymatic and/or microbial attack relative tothe first material, which can greatly improve the production rate and/orproduction level of a desired product, e.g., ethanol. Pyrolysis can alsosterilize the first and second materials.

In some embodiments, the second number average molecular weight (M_(N2))is lower than the first number average molecular weight (M_(N1)) by morethan about 10 percent, e.g., 15, 20, 25, 30, 35, 40, 50 percent, 60percent, or even more than about 75 percent.

In some instances, the second material has cellulose that has ascrystallinity (C₂) that is lower than the crystallinity (C₁) of thecellulose of the first material. For example, (C₂) can be lower than(C₁) by more than about 10 percent, e.g., 15, 20, 25, 30, 35, 40, oreven more than about 50 percent.

In some embodiments, the starting crystallinity (prior to pyrolysis) isfrom about 40 to about 87.5 percent, e.g., from about 50 to about 75percent or from about 60 to about 70 percent, and the crystallinityindex after pyrolysis is from about 10 to about 50 percent, e.g., fromabout 15 to about 45 percent or from about 20 to about 40 percent.However, in certain embodiments, e.g., after extensive pyrolysis, it ispossible to have a crystallinity index of lower than 5 percent. In someembodiments, the material after pyrolysis is substantially amorphous.

In some embodiments, the starting number average molecular weight (priorto pyrolysis) is from about 200,000 to about 3,200,000, e.g., from about250,000 to about 1,000,000 or from about 250,000 to about 700,000, andthe number average molecular weight after pyrolysis is from about 50,000to about 200,000, e.g., from about 60,000 to about 150,000 or from about70,000 to about 125,000. However, in some embodiments, e.g., afterextensive pyrolysis, it is possible to have a number average molecularweight of less than about 10,000 or even less than about 5,000.

In some embodiments, the second material can have a level of oxidation(O₂) that is higher than the level of oxidation (O₁) of the firstmaterial. A higher level of oxidation of the material can aid in itsdispersability, swellability and/or solubility, further enhancing thematerials susceptibility to chemical, enzymatic or microbial attack. Insome embodiments, to increase the level of the oxidation of the secondmaterial relative to the first material, the pyrolysis is performed inan oxidizing environment, producing a second material that is moreoxidized than the first material. For example, the second material canhave more hydroxyl groups, aldehyde groups, ketone groups, ester groupsor carboxylic acid groups, which can increase its hydrophilicity.

In some embodiments, the pyrolysis of the materials is continuous. Inother embodiments, the material is pyrolyzed for a pre-determined time,and then allowed to cool for a second pre-determined time beforepyrolyzing again.

Oxidation

One or more oxidative processing sequences can be used to processcarbon-containing materials from a wide variety of different sources toextract useful substances from the materials, and to provide partiallydegraded and/or altered material which functions as input to furtherprocessing steps and/or sequences. The oxidation conditions will varydepending on the lignin content of the feedstock, with a higher degreeof oxidation generally being desired for higher lignin contentfeedstocks.

In one method, a first material that includes cellulose having a firstnumber average molecular weight (M_(N1)) and having a first oxygencontent (O₁) is oxidized, e.g., by heating the first material in astream of air or oxygen-enriched air, to provide a second material thatincludes cellulose having a second number average molecular weight(M_(N2)) and having a second oxygen content (O₂) higher than the firstoxygen content (O₁).

Such materials can also be combined with a solid and/or a liquid. Theliquid and/or solid can include a microorganism, e.g., a bacterium,and/or an enzyme. For example, the bacterium and/or enzyme can work onthe cellulosic or lignocellulosic material to produce a fuel, such asethanol, or a coproduct, such as a protein. Fuels and coproducts aredescribed in FIBROUS MATERIALS AND COMPOSITES,” U.S. Ser. No.11/453,951, filed Jun. 15, 2006. The entire contents of each of theforegoing applications are incorporated herein by reference.

In some embodiments, the second number average molecular weight is notmore 97 percent lower than the first number average molecular weight,e.g., not more than 95 percent, 90, 85, 80, 75, 70, 65, 60, 55, 50, 45,40, 30, 20, 12.5, 10.0, 7.5, 5.0, 4.0, 3.0, 2.5, 2.0 or not more than1.0 percent lower than the first number average molecular weight. Theamount of reduction of molecular weight will depend upon theapplication. For example, in some preferred embodiments that providecomposites, the second number average molecular weight is substantiallythe same as the first number average molecular weight. In otherapplications, such as making ethanol or another fuel or coproduct, ahigher amount of molecular weight reduction is generally preferred.

In some embodiments in which the materials are used to make a fuel or acoproduct, the starting number average molecular weight (prior tooxidation) is from about 200,000 to about 3,200,000, e.g., from about250,000 to about 1,000,000 or from about 250,000 to about 700,000, andthe number average molecular weight after oxidation is from about 50,000to about 200,000, e.g., from about 60,000 to about 150,000 or from about70,000 to about 125,000. However, in some embodiments, e.g., afterextensive oxidation, it is possible to have a number average molecularweight of less than about 10,000 or even less than about 5,000.

In some embodiments, the second oxygen content is at least about fivepercent higher than the first oxygen content, e.g., 7.5 percent higher,10.0 percent higher, 12.5 percent higher, 15.0 percent higher or 17.5percent higher. In some preferred embodiments, the second oxygen contentis at least about 20.0 percent higher than the first oxygen content ofthe first material. Oxygen content is measured by elemental analysis bypyrolyzing a sample in a furnace operating at 1300° C. or higher. Asuitable elemental analyzer is the LECO CHNS-932 analyzer with a VTF-900high temperature pyrolysis furnace.

Generally, oxidation of a material occurs in an oxidizing environment.For example, the oxidation can be effected or aided by pyrolysis in anoxidizing environment, such as in air or argon enriched in air. To aidin the oxidation, various chemical agents, such as oxidants, acids orbases can be added to the material prior to or during oxidation. Forexample, a peroxide (e.g., benzoyl peroxide) can be added prior tooxidation.

Some oxidative methods of reducing recalcitrance in a biomass feedstockemploy Fenton or Fenten-type chemistry. Such methods are disclosed, forexample, in U.S. Provisional Application No. 61/139,473, filed Dec. 19,2008, the complete disclosure of which is incorporated herein byreference.

Exemplary oxidants include peroxides, such as hydrogen peroxide andbenzoyl peroxide, persulfates, such as ammonium persulfate, activatedforms of oxygen, such as ozone, permanganates, such as potassiumpermanganate, perchlorates, such as sodium perchlorate, andhypochlorites, such as sodium hypochlorite (household bleach).

In some situations, pH is maintained at or below about 5.5 duringcontact, such as between 1 and 5, between 2 and 5, between 2.5 and 5 orbetween about 3 and 5. Conditions can also include a contact period ofbetween 2 and 12 hours, e.g., between 4 and 10 hours or between 5 and 8hours. In some instances, conditions include not exceeding 300° C.,e.g., not exceeding 250, 200, 150, 100 or 50° C. In special desirableinstances, the temperature remains substantially ambient, e.g., at orabout 20-25° C.

In some desirable embodiments, the one or more oxidants are applied to afirst cellulosic or lignocellulosic material and the one or morecompounds as a gas, such as by generating ozone in-situ by irradiatingthe first cellulosic or lignocellulosic material and the one or morecompounds through air with a beam of particles, such as electrons.

In particular desirable embodiments, a first cellulosic orlignocellulosic material is firstly dispersed in water or an aqueousmedium that includes the one or more compounds dispersed and/ordissolved therein, water is removed after a soak time (e.g., loose andfree water is removed by filtration), and then the one or more oxidantsare applied to the combination as a gas, such as by generating ozonein-situ by irradiating the first cellulosic or lignocellulosic and theone or more compounds through air with a beam of particles, such aselectrons (e.g., each being accelerated by a potential difference ofbetween 3 MeV and 10 MeV). Soaking can open up interior portions tooxidation.

In some embodiments, the mixture includes one or more compounds and oneor more oxidants, and a mole ratio of the one or more compounds to theone or more oxidants is from about 1:1000 to about 1:25, such as fromabout 1:500 to about 1:25 or from about 1:100 to about 1:25.

In some desirable embodiments, the mixture further includes one or morehydroquinones, such as 2,5-dimethoxyhydroquinone (DMHQ) and/or one ormore benzoquinones, such as 2,5-dimethoxy-1,4-benzoquinone (DMBQ), whichcan aid in electron transfer reactions.

In some desirable embodiments, the one or more oxidants areelectrochemically-generated in-situ. For example, hydrogen peroxideand/or ozone can be electro-chemically produced within a contact orreaction vessel.

Other Processes to Solubilize, Reduce Recalcitrance or to Functionalize

Any of the processes of this paragraph can be used alone without any ofthe processes described herein, or in combination with any of theprocesses described herein (in any order): steam explosion, acidtreatment (including concentrated and dilute acid treatment with mineralacids, such as sulfuric acid, hydrochloric acid and organic acids, suchas trifluoroacetic acid), base treatment (e.g., treatment with lime orsodium hydroxide), UV treatment, screw extrusion treatment (see, e.g.,U.S. Patent Application Ser. No. 61/073,530, filed Nov. 18, 2008,solvent treatment (e.g., treatment with ionic liquids) and freezemilling (see, e.g., U.S. Patent Application Ser. No. 61/081,709).

Thermochemical Conversion

A thermochemical conversion process includes changing molecularstructures of carbon-containing material at elevated temperatures.Specific examples include gasification, pyrolysis, reformation, partialoxidation and mixtures of these (in any order).

Gasification converts carbon-containing materials into a synthesis gas(syngas), which can include methanol, carbon monoxide, carbon dioxideand hydrogen. Many microorganisms, such as acetogens or homoacetogensare capable of utilizing a syngas from the thermochemical conversion ofbiomass, to produce a product that includes an alcohol, a carboxylicacid, a salt of a carboxylic acid, a carboxylic acid ester or a mixtureof any of these. Gasification of biomass (e.g., cellulosic orlignocellulosic materials), can be accomplished by a variety oftechniques. For example, gasification can be accomplished utilizingstaged steam reformation with a fluidized-bed reactor in which thecarbonaceous material is first pyrolyzed in the absence of oxygen andthen the pyrolysis vapors are reformed to synthesis gas with steamproviding added hydrogen and oxygen. In such a technique, process heatcomes from burning char. Another technique utilizes a screw augerreactor in which moisture (and oxygen) are introduced at the pyrolysisstage and the process heat is generated from burning some of the gasproduced in the latter stage. Another technique utilizes entrained flowreformation in which both external steam and air are introduced in asingle-stage gasification reactor. In partial oxidation gasification,pure oxygen is utilized with no steam.

Production of Fuels, Acids, Esters and/or Other Products

A typical biomass resource contains cellulose, hemicellulose, and ligninplus lesser amounts of proteins, extractables and minerals. After one ormore of the processing steps discussed above have been performed on thebiomass, the complex carbohydrates contained in the cellulose andhemicellulose fractions can be processed into fermentable sugars,optionally, along with acid or enzymatic hydrolysis. The sugarsliberated can be converted into a variety of products, such as alcoholsor organic acids. The product obtained depends upon the microorganismutilized and the conditions under which the bioprocessing occurs.

Thus, a biomass material can be treated to reduce its recalcitranceusing any one or more of the treatment methods described herein, such aswith one or more of radiation, sonication, pyrolysis, oxidation andsteam explosion, and then at least a portion of the thus treated biomasscan be converted utilizing a microorganism to produce a product thatincludes one or more of an alcohol, a carboxylic acid, a salt of acarboxylic acid, a carboxylic acid ester or a mixture of any of these.This product can then be acidified, esterified and/or hydrogenated, toform a final product, e.g., ethanol. In some cases, acetogens orhomoacetogens, which are capable of utilizing a syngas from athermochemical conversion process, can be utilized to enhance theefficiency of the conversion.

The carboxylic acid groups in these products generally lower the pH ofthe fermentation solution, tending to inhibit fermentation with somemicroorganisms, such Pichia stipitis. Accordingly, it is in some casesdesirable to add base and/or a buffer, before or during fermentation, tobring up the pH of the solution. For example, sodium hydroxide or limecan be added to the fermentation medium to elevate the pH of the mediumto range that is optimum for the microorganism utilized.

Suitable bioprocessing methods are disclosed, for example, in U.S.Provisional Application No. 61/147,377, filed Jan. 26, 2009, thecomplete disclosure of which is incorporated herein by reference.

Generally, various microorganisms can produce a number of usefulproducts, such as a fuel, by operating on, e.g., fermenting the treatedcarbon-containing materials.

The microorganism can be a natural microorganism or an engineeredmicroorganism. For example, the microorganism can be a bacterium, e.g.,a cellulolytic bacterium, a fungus, e.g., a yeast, a plant or a protist,e.g., an algae, a protozoa or a fungus-like protist, e.g., a slime mold.When the organisms are compatible, mixtures of organisms can beutilized. The microorganism can be an aerobe or an anaerobe. Themicroorganism can be a homofermentative microorganism (produces a singleor a substantially single end product). The microorganism can be ahomoacetogenic microorganism, a homolactic microorganism, a propionicacid bacterium, a butyric acid bacterium, a succinic acid bacterium or a3-hydroxypropionic acid bacterium. The microorganism can be of a genusselected from the group Clostridium, Lactobacillus, Moorella,Thermoanaerobacter, Proprionibacterium, Propionispera,Anaerobiospirillum, and Bacteroides. In specific instances, themicroorganism can be Clostridium formicoaceticum, Clostridium butyricum,Moorella thermoacetica, Thermoanaerobacter kivui, Lactobacillusdelbrukii, Propionibacterium acidipropionici, Propionispera arboris,Anaerobiospirillum succinicproducens, Bacteroides amylophilus orBacteroides ruminicola. For example, the microorganism can be arecombinant microorganism engineered to produce a desired product, suchas a recombinant Escherichia coli transformed with one or more genescapable of encoding proteins that direct the production of the desiredproduct is used (see, e.g., U.S. Pat. No. 6,852,517, issued Feb. 8,2005).

Bacteria that can ferment biomass to ethanol and other products include,e.g., Zymomonas mobilis and Clostridium thermocellum (Philippidis, 1996,supra). Leschine et al. (International Journal of Systematic andEvolutionary Microbiology 2002, 52, 1155-1160) isolated an anaerobic,mesophilic, cellulolytic bacterium from forest soil, Clostridiumphytofermentans sp. nov., which converts cellulose to ethanol.

Fermentation of biomass to ethanol and other products may be carried outusing certain types of thermophilic or genetically engineeredmicroorganisms, such Thermoanaerobacter species, including T. mathranii,and yeast species such as Pichia species. An example of a strain of T.mathranii is A3M4 described in Sonne-Hansen et al. (Applied Microbiologyand Biotechnology 1993, 38, 537-541) or Ahring et al. (Arch. Microbiol.1997, 168, 114-119).

To aid in the breakdown of the materials that include the cellulose(treated by any method described herein or even untreated), one or moreenzymes, e.g., a cellulolytic enzyme can be utilized. In someembodiments, the materials that include the cellulose are first treatedwith the enzyme, e.g., by combining the material and the enzyme in anaqueous solution. This material can then be combined with anymicroorganism described herein. In other embodiments, the materials thatinclude the cellulose, the one or more enzymes and the microorganism arecombined concurrently, e.g., by combining in an aqueous solution.

Fermentation is generally conducted in an aqueous growth medium, whichcan contain a nitrogen source or other nutrient source, e.g., urea,along with vitamins and trace minerals and metals. It is generallypreferable that the growth medium be sterile, or at least have a lowmicrobial load, e.g., bacterial count. Sterilization of the growthmedium may be accomplished in any desired manner. However, in preferredimplementations, sterilization is accomplished by irradiating the growthmedium or the individual components of the growth medium prior tomixing. The dosage of radiation is generally as low as possible whilestill obtaining adequate results, in order to minimize energyconsumption and resulting cost. For example, in many instances, thegrowth medium itself or components of the growth medium can be treatedwith a radiation dose of less than 5 Mrad, such as less than 4, 3, 2 or1 Mrad. In specific instances, the growth medium is treated with a doseof between about 1 and 3 Mrad.

OTHER EMBODIMENTS

A number of embodiments have been described. Nevertheless, it will beunderstood that various modifications may be made without departing fromthe spirit and scope of the disclosure.

While it is possible to perform all the processes described herein allat one physical location, in some embodiments, the processes arecompleted at multiple sites, and/or may be performed during transport.

Lignin liberated in any process described herein can be captured andutilized. For example, the lignin can be used as captured as a plastic,or it can be synthetically upgraded to other plastics. In someinstances, it can be utilized as an energy source, e.g., burned toprovide heat. In some instances, it can also be converted tolignosulfonates, which can be utilized as binders, dispersants,emulsifiers or as sequestrants. The measurement of the lignin content ofthe starting feedstock can be used in process control in suchlignin-capturing processes.

When used as a binder, the lignin or a lignosulfonate can, e.g., beutilized in coal briquettes, in ceramics, for binding carbon black, forbinding fertilizers and herbicides, as a dust suppressant, in the makingof plywood and particle board, for binding animal feeds, as a binder forfiberglass, as a binder in linoleum paste and as a soil stabilizer.

As a dispersant, the lignin or lignosulfonates can be used, e.g.,concrete mixes, clay and ceramics, dyes and pigments, leather tanningand in gypsum board.

As an emulsifier, the lignin or lignosulfonates can be used, e.g., inasphalt, pigments and dyes, pesticides and wax emulsions.

As a sequestrant, the lignin or lignosulfonates can be used, e.g., inmico-nutrient systems, cleaning compounds and water treatment systems,e.g., for boiler and cooling systems.

As a heating source, lignin generally has a higher energy content thanholocellulose (cellulose and hemicellulose) since it contains morecarbon than homocellulose. For example, dry lignin can have an energycontent of between about 11,000 and 12,500 BTU per pound, compared to7,000 an 8,000 BTU per pound of holocellulose. As such, lignin can bedensified and converted into briquettes and pellets for burning. Forexample, the lignin can be converted into pellets by any methoddescribed herein. For a slower burning pellet or briquette, the lignincan be crosslinked, such as applying a radiation dose of between about0.5 Mrad and 5 Mrad. Crosslinking can make a slower burning form factor.The form factor, such as a pellet or briquette, can be converted to a“synthetic coal” or charcoal by pyrolyzing in the absence of air, e.g.,at between 400 and 950° C. Prior to pyrolyzing, it can be desirable tocrosslink the lignin to maintain structural integrity.

Accordingly, other embodiments are within the scope of the followingclaims.

What is claimed is:
 1. A processing facility configured to process alignocellulosic material comprising: an ionizing radiation system totreat the lignocellulosic material prior to fermentation, oxidizingequipment comprising a gas supply configured to provide an oxidizingenvironment of air or oxygen to the ionizing radiation system, a lignincontent measurement system configured to measure a lignin content of thelignocellulosic material prior to fermentation, and a fermentationsystem to ferment a treated lignocellulosic material from the ionizingradiation system, wherein the ionizing radiation system comprises a doseor dose rate as an adjustable process parameter that can be adjusted,based on the lignin content determined by the lignin content measurementsystem, to reduce a recalcitrance of the lignocellulosic material. 2.The processing facility of claim 1, further including a mechanicaltreatment system to treat the lignocellulosic material prior tofermentation, wherein the mechanical treatment system includes a secondadjustable process parameter that can be adjusted, based on the lignincontent determined by the lignin content measurement system, to reducethe recalcitrance of the lignocellulosic material.
 3. The processingfacility of claim 1, wherein the ionizing radiation system comprises anelectron beam irradiation device, the device configured to provide anelectron beam having an energy of at least 1 MeV.
 4. The processingfacility of claim 1, further comprising a system configured forcapturing lignin.
 5. The processing facility of claim 1, wherein thefacility is configured to process more than one type of lignocellulosicmaterial.
 6. The processing facility of claim 1, wherein thefermentation system comprises a fermentative microorganism.
 7. Theprocessing facility of claim 6, further comprising a saccharificationsystem to saccharify the treated lignocellulosic material prior tofermentation.
 8. The processing facility of claim 7, wherein thesaccharification system comprises a cellulase.